4 | Sidel News 19 April 2005

i n n o v a t i o n i n n o vat i o nblowing & coating

Sidel News 19 April 2005 |5

blowing & coating

SBO Universal,

Bottle blowing costs reduced up to 20%

PET BOTTLE BLOWING COSTS SLASHED BY UP TO 20% COMPARED WITH ITS SBO SERIES2 EQUIPMENT. THATS THE BREAKTHROUGH OF SIDELS NEW GENERATION OF SBO UNIVERSAL BLOWING MACHINES MAKING THEIR GLOBAL DBUT AT THE INTERPACK TRADE FAIR.

The new generation of SBO Universal blowing machines from Sidel is the culmination of three years of intense R&D work to design, validate, and qualify new manufactu-ring solutions for plastic bottles pro-duced at very high speeds and ranging from 0.25 L to 3 L in size. A 23% jump in productivity and a 25% drop in ope-rating costs result in a 20% reduction in bottle blowing costs. These per-formance improvements stem from efforts that have not only targeted blowing machine advances, they have also involved a full-blown bottle solutions development program specifically for high-speed applications.

Versatile SBO Universal blowing machinesIt is the huge array of applications, capacities, and package types served by the new range of Sidel SBO Universal blowing machines that makes this new generation so multi-faceted.

BLOWING MACHINES FOR ALL YOUR PACKAGING LINES Whether its still or sparkling water, carbonated or sensitive drinks, sauces or detergents, Sidels SBO Universal

blowing machines can meet the challenge of your production environment for all of your products, liquid foods and non-food liquids packaged in plastic packaging.

SOLUTIONS FOR ALL TECHNICAL CHALLENGES OF YOUR PACKAGE.In addition to producing standard bottles, Sidels SBO Universal equipment is also designed for special packages made using the heat resistance (HR) process for hot fill bottles or preferential heating (CP) to produce flat or complex-shaped packaging. The SBO Universal range produces plastic packages in the widest variety of shapes for all types of appli-cations.

Productivity jumps by

23% (bottles/year)

Operating costs fall by

up to 25% (euros/year)

Bottle blowing costs

decrease by 20%(euros/bottles)

1014

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6 | Sidel News 19 April 2005 Sidel News 19 April 2005 |7

i n n o v a t i o n i n n o vat i o nblowing & coating blowing & coating

MACHINES AVAILABLE FOR A WIDE RANGE OF CAPACITIES Like the Series2+, SBO Universal equi-pment is designed to produce packages ranging in size from 0.25 L to 3 L on standard models. In addition, these machines can be specially configured to produce packages as large as 5 or 6 liters.

SINGLE BLOWING MACHINE FOR BOTH PET AND PP As new polymers have hit the market, Sidel has led research efforts on both raw materials and processes. The new range of SBO Universal equipment can be used to produce PET or PP packa-ges without modifying the machines configuration; and both can be manu-factured at similar output rates.

Productivity up to 23% higher

OUTPUT RATES UP 12.5% TO 1,800 BOTTLES PER MOLD Thanks to the development of new machine kinematics and a new oven with a 40 mm pitch to maintain heating times, Sidel can now confidently offer output rates of 1,800 bottles per mold for many types of packages. The machine is not the only part of the equation that has been modified. Preforms and bottles have a new design, as do molds that are better adapted to shrinkage laws. The process has also been adapted to higher speeds. All of these factors combined contribute to the overall increase in productivity to 1,800 bottles per mold.

MAINTENANCE TIMES 25% FASTER The SBO Universal equipment sports a new, brushed aluminum housing that not only blends with other Sidel equip-ment on the line, it also offers greater functionality. A new catwalk provides better access to the feeder. Side openings of the oven doors and a new blowing wheel frame have all been introduced for easier operator access to machine systems for maintenance procedures. New maintenance-free com-ponents and an improved maintenance plan also reduce maintenance times.

FORMAT CHANGEOVER TIMES 20% FASTER A new, patented mold base design and a new stretching stopper without a fastening device both help reduce format changeover times. The new housing also makes the machine more accessible and ergonomic. Finally, all of the feeder parameters and preform dimensions are recorded in the process recipe so that production restarts are much faster.

The guide rail is lifetime lubricated.

Totally revamped kinematics and lighter transfer arms help boost speeds to 1,800 b/h/m.

Shrinkage laws on new molds are designed for high output rates.

The new blowing station, with 27% less dead space,

offers significant reductions in air consumption.

Maximum mechanical output rates in bottles/hourSBO 6 10,800

SBO 8 14,400

SBO 10 18,000

SBO 14 25,200

SBO 16 28,800

SBO 20 36,000

Development phase 51,000

All of the systems on the SBO Universal blowing machine are far more accessible.

At Interpack 2005, Sidel is exhibiting a SBO20 machine (36,000 b/h).

At Fispal 2005, Sidel is exhibiting a SBO10 machine (18,000 b/h).

Operating costs 25% lower

AIR CONSUMPTION REDUCEDAir consumption reduced. The new blowing station, with 27% less dead space in the air circuits, reduces blowing air consumption. The air recy-

cling option accompanied by a flow meter saves at least 15% in air consump-tion. Furthermore, the development of special bottle shapes makes

it possible to perform low pressure blowing. Because of these improvements, custo-mers can reduce the size of

their compressor, thereby resulting in an overall purchase price thats about 15% less.

ELECTRICITY CONSUMPTION 15% LOWER Even as speeds increase to 1,800 b/h/m, preform heating time remains much the same thanks to a new oven with a 40 mm pitch that does not require additional heating power. The new heating zone regulation system (individual settings on all oven lamps fully controlled from the PCC along with individual lamp positioning) helps reduce electricity consumption by about 15% on average. A measuring device is built into the system to measure electricity consumption during blowing machine production. The system then posts that information on the HMI (Human Machine Interface) screen.

secure production. Ejection zones for poorly loaded preforms or defective, nonconforming, or poorly engaged bottles help reduce unscheduled production shutdowns.

BOTTLE QUALITY WITH A MAXIMUM SCRAP RATE OF 0.1%Sidel has made significant advances in preform thermal conditioning. The radiation oven design, which enables Sidel blowing machines to produce high-quality packages, is better than ever with superior repeatability and stability of the heating profile. In addition, a built-in preform inspection module (optional) and in line bottle quality control (optional) further enhance the system. The equipments

heating flexibility and its ability to fully control production parameters increases process ranges. It also impro-ves mechanical strength of bottles and makes it possible to produce lighter weight containers.

GUARANTEED YIELD OF 97% The new preform infeed design reduces low levels and improves the blowing machines yield by at least 2%. The recycling belt keeps preforms from getting jammed inside one another. Orienting rollers feature a novel design. If preforms are stuck together or are too numerous, they are automatically ejected and returned to the hopper via a recycling conveyor built-in under-neath the rollers. The new automatic controls on the blowing machine manage preform feeding with a control loop to drive roller speed and the elevator column to maintain the cor-rect number of preforms to feed the blowing machine. A new machine pro-gram manages shutdowns and ensures

New preform infeed system improves yield on the blowing

machine by 2%.

LESS MANPOWER REQUIRED FOR MACHINE OPERATION In addition to new housing, which makes the system more accessible and ergonomic, the new machine control station is more user-friendly and intuitive. With a 17 screen and XP interface, it simplifies operation of the blowing machine, supervision of production quality and process, yield tracking, machine settings, and maintenance. Since the EIT system comes standard on all of the new equipment, production and shutdowns are automatically tracked, and sources of shutdowns are analyzed to get the system back up and running quickly.

REDUCED SPARE PARTS COSTS FOR MAINTENANCE The new SBO Universal range guarantees lower costs for maintenance and con-

sumable spare parts. New maintenance-free components help to streamline the maintenance plan and reduce machine downtime. New kinematics, with less inertia and reduced mecha-nical stresses, the new blowing station, new transfer arms, and a new air rotary union all result in fewer scheduled maintenance shutdowns.

SMALLER FOOTPRINT The blowing machines overall dimen-sions are significantly reduced because the electric cabinet is now built into the end of the oven. The new preform distributor is also more compact. With more space, customers can add addi-tional equipment or can use the area to store molds and custom parts close to the machine.

WIDE ARRAY OF OPTIONS From process to maintenance, energy consumption, and process accessories, Sidel has developed a comprehensive catalogue of options customized for your packages specifications. These options optimize production performance to manufacture high quality bottles at low cost. Options to enhance production flexibility and hygiene are also available.

BENEFITS FOR THE ENTIRE PACKAGING LINEThe 2% increase in yield of the SBO Universal blowing machine translates to better yield of the entire line. The increased speed of the blowing machine to 1,800 bottles/hour/mold now makes it possible for customers to choose a smaller model blowing machine and keep line output rate at the same level. This lowers the lines overall investment cost. And because format changeover times on the blowing machine, generally requiring the most time of any equipment on the line, are now reduced, this results in a drop in format changeover times for the entire line. And because air consumption is lower on the new equipment, customers can select a smaller size compressor, thus reducing investment costs even further. When purchased in the Combi version, the SBO Universal offers even greater efficiency in an integrated blowing, filling, capping solution.

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i n n o v a t i o n i n n o vat i o nblowing & coating filling systems

When deciding on the best method to fill still, carbo-nated, or pulp-containing beverages, that decision largely depends on the nature of your product. Sidels vast knowledge about the various packaging require-ments of all liquid foods has led to the development of its new fillers that target particular filling environments. The Select environment is the perfect solution for stable, slightly sensitive beverages sold at room temperature.

Flow meter filling a simple and reliable principleSF Select FMw (Flow Meter for water) and SF Select FMg (Flow Meter for gaseous) fillers are start-of-the-art equipment designed to fill PET bottles ranging from 0.25 L to 3 L in size. These fillers use electromagnetic flow meter technology for better control of filling parameters.Unlike traditional flow meter fillers based on a centralized and remote control system, the FMw and FMg fillers are controlled at the filling stations, which are equipped with independent flow meters with onboard dosing intelligence.

Each flow meter directly controls each of the valves and independently operates dosing and self-correction processes for each filling valve.

All of these compact, leaktight filling stations are linked to the main controller (standard commercial controller) by field bus. The controller transfers the recipe to each filling station with information on volume and specific process parameters for the bottle to be filled and for the product being filled. The recipes are accessible from the operator interface. These recipes simplify the filling process parame-terization and facilitate product changeover. At the end of every filling sequence, the control device feedbacks to the main controller providing information on product quantity dosed and any details regarding anomalies encountered during production. This information, recorded at the ope-rator interface, makes it possible to perform a statistical analysis of the overall dosing process and the process at each filling station.

Sidel introduces new filling intelligence

SIDEL CONTINUES TO INNOVATE IN THE FIELD OF FILLING STILL AND CARBONATED BEVERAGES IN PET BOTTLES. WITH THE LAUNCH OF ITS NEW FLOW METER FILLERS, SIDEL OFFERS A SIMPLE, RELIABLE TECHNOLOGY TO COMPLETELY CONTROL FILLING PARAMETERS AND KEEP PRODUCTS SAFE.

Filling without contact between bottle and filling valve guarantees superior hygiene for water filling applications.

Building the cabinet into the end of the oven significantly reduces the blowing machines footprint.

The 40 mm pitch oven ensures identical heating times at 1,800 b/h/m.

The new operator interface simplifies blowing machine operation.

At Interpack 2005, Sidel is exhibiting an SF Select FMw filler equipped with 50 rinsing nozzles, 60 filling valves and 15 capping heads.